Electronic smoking article with improved storage of aerosol precursor compositions

ABSTRACT

The present disclosure relates to electronic smoking articles exhibiting improved moisture control of a reservoir contained therein. The reservoir can be formed of fibrous materials, such as cellulose acetate fiber, thermoplastic fiber, non-thermoplastic fiber, or a combination thereof. The disclosure further provides methods for forming electronic smoking articles and methods of packaging electronic smoking articles (including cartridges thereof) so as to improve moisture control of the reservoir.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices such assmoking articles, and more particularly to means for providing anindication of a status of such devices to a user thereof. The smokingarticles may be configured to heat a material, which may be made orderived from tobacco or otherwise incorporate tobacco, to form aninhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. patent application Ser. No.13/432,406, filed Mar. 28, 2012, U.S. patent application Ser. No.13/536,438, filed Jun. 28, 2012, U.S. patent application Ser. No.13/602,871, filed Sep. 4, 2012, and U.S. patent application Ser. No.13/647,000, filed Oct. 8, 2012, which are incorporated herein byreference.

Certain tobacco products that have employed electrical energy to produceheat for smoke or aerosol formation, and in particular, certain productsthat have been referred to as electronic cigarette products, have beencommercially available throughout the world. Representative productsthat resemble many of the attributes of traditional types of cigarettes,cigars or pipes have been marketed as ACCORD® by Philip MorrisIncorporated; ALPHA™, JOYE 510™ and M4™ by InnoVapor LLC; CIRRUS™ andFLING™ by White Cloud Cigarettes; COHITA™, COLIBRI™, ELITE CLASSIC™,MAGNUM™, PHANTOM™ and SENSE™ by Epuffer® International Inc.; DUOPRO™,STORM™ and VAPORKING® by Electronic Cigarettes, Inc.; EGAR™ by EgarAustralia; eGo-C™ and eGo-T™ by Joyetech; ELUSION™ by Elusion UK Ltd;EONSMOKE® by Eonsmoke LLC; GREEN SMOKE® by Green Smoke Inc. USA;GREENARETTE™ by Greenarette LLC; HALLIGAN™, HENDU™, JET™, MAXXQ™, PINK™and PITBULL™ by Smoke Stik®; HEATBAR™ by Philip Morris International,Inc.; HYDRO IMPERIAL™ and LXE™ from Crown7; LOGIC™ and THE CUBAN™ byLOGIC Technology; LUCI® by Luciano Smokes Inc.; METRO® by Nicotek, LLC;NJOY® and ONEJOY™ by Sottera, Inc.; NO. 7™ by SS Choice LLC; PREMIUMELECTRONIC CIGARETTE™ by PremiumEstore LLC; RAPP E-MYSTICK™ by RuyanAmerica, Inc.; RED DRAGON™ by Red Dragon Products, LLC; RUYAN® by RuyanGroup (Holdings) Ltd.; SMART SMOKER® by The Smart Smoking ElectronicCigarette Company Ltd.; SMOKE ASSIST® by Coastline Products LLC; SMOKINGEVERYWHERE® by Smoking Everywhere, Inc.; V2CIGS™ by VMR Products LLC;VAPOR NINE™ by VaporNine LLC; VAPOR4LIFE® by Vapor 4 Life, Inc.; VEPPO™by E-CigaretteDirect, LLC and VUSE® by R. J. Reynolds Vapor Company. Yetother electrically powered aerosol delivery devices, and in particularthose devices that have been characterized as so-called electroniccigarettes, have been marketed under the tradenames BLU™; COOLERVISIONS™; DIRECT E-CIG™; DRAGONFLY™; EMIST™; EVERSMOKE™; GAMUCCI®;HYBRID FLAME™; KNIGHT STICKS™; ROYAL BLUES™; SMOKETIP® and SOUTH BEACHSMOKE™.

It would be desirable to provide a smoking article that employs heatproduced by electrical energy to provide the sensations of cigarette,cigar, or pipe smoking, that does so without combusting tobacco to anysignificant degree, that does so without the need of a combustion heatsource, and that does so without necessarily delivering considerablequantities of incomplete combustion and pyrolysis products. Further,advances with respect to manufacturing electronic smoking articles wouldbe desirable.

BRIEF SUMMARY

The present disclosure provides smoking articles and related componentsand methods of manufacture and packaging. The disclosure particularlyprovides for devices and methods that can control transfer of moistureto and from a reservoir, particularly a reservoir comprising a woven ornonwoven fabric, such as formed from cellulose acetate or a similarfiber or fibers.

In some embodiments, the present disclosure provides an electronicsmoking article. The electronic smoking article can comprise a housingand a reservoir within the housing that is configured to hold an aerosolprecursor fluid. The reservoir can comprise a woven or nonwoven fabricexhibiting specific properties that are useful in controlling moistureabsorption and/or adsorption or, additionally or in the alternative,controlling moisture release. Moisture release particularly may occur inknown devices in the form of sweating, wherein excess liquid,particularly water, may be released from a reservoir during storage orother handling, such release not being related to aerosolization viaactivation of an associated heater. Such release of liquid within thehousing can be undesirable and may result in deleterious effects on oneor more components of the electronic smoking article and/or may resultin leakage from the housing to the surrounding environment, such aswithin packaging or onto a consumer.

In some embodiments, a woven or nonwoven fabric may be useful in that itexhibits a basis weight that can provide a useful effect in liquidcontrol. For example, a woven or nonwoven fabric used in a reservoiraccording to the present disclosure can have a basis weight of about 120gsm or greater, particularly about 130 or greater. Further useful basisweights are further disclosed herein. In some embodiments, a pluralityof layers of woven fabrics, non-woven fabrics, or combinations thereofmay be utilized, the combination of the layers exhibiting the basisweight described herein.

In some embodiments, a reservoir in a smoking article according to thepresent disclosure may be substantially shaped as a cylinder having ahollow interior portion (although other shapes are also encompassed asotherwise disclosed herein). Although a variety of fibers may be used informing a woven or nonwoven fabric according to the present disclosure,the woven or nonwoven fabric particularly may comprise celluloseacetate. A woven or nonwoven fabric used in a reservoir according to thepresent disclosure can have a thickness (e.g., the thickness of acylinder wall) of about 1 mm to about 4 mm.

Utilizing reservoir fabrics having a basis weight as described hereincan be useful in relation to preventing capillary loses. For example,when a liquid-loaded fabric is in close proximity to another material,liquid may pass from the fabric to the other material through capillaryaction. Capillary loses, such as between a reservoir and a wall of anelectronic smoking article, can be reduced according to the presentdisclosure.

In some embodiments, it can be useful for the aerosol precursorcomposition (particularly a liquid composition) to be applied to thereservoir in a limited content. More particularly, the amount of theaerosol precursor composition applied to the reservoir may be defined inrelation to the saturation capacity of the reservoir. For example,reservoir materials according to some embodiments of the presentdisclosure can have a saturation capacity of up to about 2,000% byweight of the reservoir, particularly about 800% to about 2,000% byweight. The weight of aerosol precursor fluid in the reservoir relativeto the saturation capacity of the reservoir can be no greater than about80% or no greater than about 60%. In other words, the reservoir may beloaded with a weight of aerosol precursor fluid that is no greater thanabout 80% of the saturation capacity of the reservoir.

It also may be useful to limit the water content of an aerosol precursorcomposition that is added to a reservoir. For example, an aerosolprecursor composition added to reservoir according to the presentdisclosure can include water in amount that is greater than about 0.1%and is less than about 15% by weight.

An electronic smoking article according to the present disclosurefurther can comprise an atomizer. In some embodiments, an atomizer maycomprise a continuous, elongated wick having two opposing ends, a heaterin connection with the wick and positioned at about a midpoint thereof,and electrically conducting terminals positioned in physical contactwith the wick and in electrical connection with the heater.

In some embodiments, a combined housing and reservoir may define acartridge body. As such, a smoking article according to the presentdisclosure further can comprise a second housing that includes a powersource and/or a controller. The second housing thus may define a controlbody or a power body. The second housing defining the control body orpower body can be removably attached to the housing comprising thereservoir (i.e., the cartridge body).

In further embodiments, an electronic smoking article according to thepresent disclosure may comprise a housing having an air inlet adaptedfor entry of air into the housing and an air outlet adapted for exit ofa formed aerosol, the inlet and the outlet having an air passagetherebetween. The smoking article also can comprise a reservoir withinthe housing that is configured to hold an aerosol precursor fluid and aheater in fluid communication with the reservoir. The heater may bepositioned at least partially within the air passage. Still further, thesmoking article can include a first check valve positioned at the airinlet and a second check valve positioned at the air outlet. Inparticular, the first check valve and the second check valve can beadapted to open only in the direction of air flow from the air inlet tothe air outlet. Specifically, the first check valve and the second checkvalve can both be one way check valves. In particular embodiments, atleast one of the first check valve and the second check valve can form aseal that is impermeable to liquid and aerosol when in the closedposition.

In some embodiments, a smoking article according to the presentdisclosure may comprise a housing including a reservoir that isconfigured to hold an aerosol precursor fluid. The smoking article alsocan comprise an absorptive material that is separate from the reservoir.The absorptive material specifically may be a lining on an interior wallof the housing. In some embodiments, the absorptive lining may belocated only at one or both of the first end and the second end of thehousing. The absorptive material can be adapted to absorb any freeliquid within the housing—e.g., any liquid that escapes from thereservoir or liquid vapor or the like that may enter the housing.Specifically, the absorptive material can be configured topreferentially absorb hydrophilic liquids, particularly water. Thepresence of a substantially dry, absorptive material in the housing witha reservoir that is already filled with an aerosol precursor compositioncan be beneficial in that ambient water vapor entering the housing maybe preferentially absorbed by the absorptive material rather than thereservoir. Further, any sweating by the reservoir may be absorbed by theabsorptive material rather than escaping from the housing or freelymoving within the housing where it may contact other parts, such as theheater.

In further embodiments, a reservoir utilized in a device according tothe present disclosure may be enclosed by a layer within the housing ofthe device. For example, the layer can be a liquid and/or vaporimpermeable container, such as a bag. The container can include asealable opening through which a liquid transport element can extend todeliver liquid from the reservoir inside the container to a heateroutside the container. In other embodiments, the layer can be formed ofa material that is liquid impermeable but vapor permeable. As such,liquid can be prevented from passing through the container, butentraining air can be allowed to pass into the container, and the vaporentrained in the air (e.g., an aerosol) can be allowed to pass out ofthe container.

In still other embodiments, a reservoir can comprise a container, tank,or the like in which the aerosol precursor composition is contained andwhich is openable and closable for release of the aerosol precursorcomposition. For example, a valve can be provided to allow exit ofaliquots of the aerosol precursor composition only immediately prior tovaporization.

In some embodiments, the present disclosure further can provide a methodof assembling an electronic smoking article. For example, the method cancomprise providing a reservoir that is configured to hold an aerosolprecursor fluid, the reservoir comprising a woven or nonwoven fabric;inserting the reservoir into a hollow housing; and adding the aerosolprecursor fluid to the reservoir before or after said inserting. Incertain embodiments, the assembly can be carried out under an ambientrelative humidity that is below a defined value. For example, assemblycan be carried out under an ambient relative humidity of no greater thanabout 40%. In some embodiments, the assembly can be carried out under aninert atmosphere. For example, the inert atmosphere can be a noble gasatmosphere, such as an argon atmosphere.

In some embodiments, the assembly method can comprise engaging an openend of the housing with a cap. The method specifically can comprisecrimping the housing to the cap so as to establish a non-hermetic sealbetween the housing and the cap that prevents passage of liquid(specifically water) therethrough but may allow passage of gas or vaportherethrough.

In still further embodiments, the present disclosure provides methods ofpackaging an electronic cigarette or a component thereof (e.g., acartridge body). For example, the method can comprise: providing thecartridge with a reservoir therein, the reservoir comprising a woven ornonwoven fabric and having an aerosol precursor fluid therein; andpositioning the cartridge within a non-hermetically sealed displaypackage formed of a material that is substantially impermeable to watervapor. In various embodiments, the packaging method further can becharacterized in that at least one of the following conditions is met:any opening in the non-hermetically sealed display package is coveredwith a water-tight sealing tape; a desiccant is included within thenon-hermetically sealed display package; a humidity control device isincluded within the non-hermetically sealed display package, thehumidity control device being adapted to maintain a relative humiditywithin the package of about 5% to about 50%; and the cartridge isenclosed by a polymeric barrier within the non-hermetically sealeddisplay package. In embodiments including a polymeric barrier, thebarrier can be lining the interior of the non-hermetically sealeddisplay package. In particular embodiments, the polymeric barrier can bea blister package encasing the cartridge.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a sectional view through an embodiment of a smokingarticle according to an embodiment of the present disclosure;

FIG. 2 illustrates a sectional view through an embodiment of a smokingarticle according to a further embodiment of the present disclosure;

FIG. 3 illustrates an exploded view of an atomizer according to anembodiment of the present disclosure including a reservoir, a wick, anda heater; and

FIG. 4 illustrates a sectional view through an embodiment of a cartridgeaccording to the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural referents unless the context clearly dictates otherwise.

The present disclosure provides descriptions of aerosol delivery devicesor smoking articles, such as so-called “e-cigarettes.” It should beunderstood that the mechanisms, components, features, and methods may beembodied in many different forms and associated with a variety ofarticles.

In this regard, the present disclosure provides descriptions of aerosoldelivery devices that use electrical energy to heat a material(preferably without pyrolyzing or combusting the material to anysignificant degree) to form an inhalable substance; such articles mostpreferably being sufficiently compact to be considered “hand-held”devices. An aerosol delivery device may provide some or all of thesensations (e.g., inhalation and exhalation rituals, types of tastes orflavors, organoleptic effects, physical feel, use rituals, visual cuessuch as those provided by visible aerosol, and the like) of smoking acigarette, cigar, or pipe, without any substantial degree of pyrolysisor combustion of any component of that article or device. The aerosoldelivery device may not produce smoke in the sense of the aerosolresulting from by-products of combustion or pyrolysis of tobacco, butrather, that the article or device may yield vapors (including vaporswithin aerosols that can be considered to be visible aerosols that mightbe considered to be described as smoke-like) resulting fromvolatilization or vaporization of certain components of the article ordevice. In highly preferred embodiments, aerosol delivery devices mayincorporate tobacco and/or components derived from tobacco.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles, smoking articles, ormedicament delivery articles. Thus, such articles or devices can beadapted so as to provide one or more substances (e.g., flavors and/orpharmaceutical active ingredients) in an inhalable form or state. Forexample, inhalable substances can be substantially in the form of avapor (i.e., a substance that is in the gas phase at a temperature lowerthan its critical point). Alternatively, inhalable substances can be inthe form of an aerosol (i.e., a suspension of fine solid particles orliquid droplets in a gas). For purposes of simplicity, the term“aerosol” as used herein is meant to include vapors, gases and aerosolsof a form or type suitable for human inhalation, whether or not visible,and whether or not of a form that might be considered to be smoke-like.

In use, aerosol delivery devices of the present disclosure may besubjected to many of the physical actions employed by an individual inusing a traditional type of smoking article (e.g., a cigarette, cigar orpipe that is employed by lighting and inhaling tobacco). For example,the user of an aerosol delivery device of the present disclosure canhold that article much like a traditional type of smoking article, drawon one end of that article for inhalation of aerosol produced by thatarticle, take puffs at selected intervals of time, etc.

Aerosol delivery devices of the present disclosure generally include anumber of components provided within an outer body or shell. The overalldesign of the outer body or shell can vary, and the format orconfiguration of the outer body that can define the overall size andshape of the aerosol delivery device can vary. Typically, an elongatedbody resembling the shape of a cigarette or cigar can be a formed from asingle, unitary shell; or the elongated body can be formed of two ormore separable pieces. For example, an aerosol delivery device cancomprise an elongated shell or body that can be substantially tubular inshape and, as such, resemble the shape of a conventional cigarette orcigar. In one embodiment, all of the components of the aerosol deliverydevice are contained within one outer body or shell. Alternatively, anaerosol delivery device can comprise two or more shells that are joinedand are separable. For example, an aerosol delivery device can possessat one end a control body comprising an outer body or shell containingone or more reusable components (e.g., a rechargeable battery andvarious electronics for controlling the operation of that article), andat the other end and removably attached thereto an outer body or shellcontaining a disposable portion (e.g., a disposable flavor-containingcartridge). More specific formats, configurations and arrangements ofcomponents within the single shell type of unit or within a multi-pieceseparable shell type of unit will be evident in light of the furtherdisclosure provided herein. Additionally, various aerosol deliverydevice designs and component arrangements can be appreciated uponconsideration of the commercially available electronic aerosol deliverydevices, such as those representative products listed in the backgroundart section of the present disclosure.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and ceasing power for heat generation, such asby controlling electrical current flow the power source to othercomponents of the article—e.g., a microcontroller), a heater or heatgeneration component (e.g., an electrical resistance heating element orcomponent commonly referred to as an “atomizer”), and an aerosolprecursor composition (e.g., commonly a liquid capable of yielding anaerosol upon application of sufficient heat, such as ingredientscommonly referred to as “smoke juice,” “e-liquid” and “e-juice”), and amouthend region or tip for allowing draw upon the aerosol deliverydevice for aerosol inhalation (e.g., a defined air flow path through thearticle such that aerosol generated can be withdrawn therefrom upondraw). Exemplary formulations for aerosol precursor materials that maybe used according to the present disclosure are described in U.S. Pat.Pub. No. 2013/0008457 to Zheng et al., the disclosure of which isincorporated herein by reference in its entirety.

Alignment of the components within the aerosol delivery device can vary.In specific embodiments, the aerosol precursor composition can belocated near an end of the article (e.g., within a cartridge, which incertain circumstances can be replaceable and disposable), which may beproximal to the mouth of a user so as to maximize aerosol delivery tothe user. Other configurations, however, are not excluded. Generally,the heating element can be positioned sufficiently near the aerosolprecursor composition so that heat from the heating element canvolatilize the aerosol precursor (as well as one or more flavorants,medicaments, or the like that may likewise be provided for delivery to auser) and form an aerosol for delivery to the user. When the heatingelement heats the aerosol precursor composition, an aerosol is formed,released, or generated in a physical form suitable for inhalation by aconsumer. It should be noted that the foregoing terms are meant to beinterchangeable such that reference to release, releasing, releases, orreleased includes form or generate, forming or generating, forms orgenerates, and formed or generated. Specifically, an inhalable substanceis released in the form of a vapor or aerosol or mixture thereof.Additionally, the selection of various aerosol delivery devicecomponents can be appreciated upon consideration of the commerciallyavailable electronic aerosol delivery devices, such as thoserepresentative products listed in the background art section of thepresent disclosure.

An aerosol delivery device incorporates a battery or other electricalpower source to provide current flow sufficient to provide variousfunctionalities to the article, such as resistive heating, powering ofcontrol systems, powering of indicators, and the like. The power sourcecan take on various embodiments. Preferably, the power source is able todeliver sufficient power to rapidly heat the heating member to providefor aerosol formation and power the article through use for the desiredduration of time. The power source preferably is sized to fitconveniently within the aerosol delivery device so that the aerosoldelivery device can be easily handled; and additionally, a preferredpower source is of a sufficiently light weight to not detract from adesirable smoking experience.

One example embodiment of an aerosol delivery device 100 is provided inFIG. 1. As seen in the cross-section illustrated therein, the aerosoldelivery device 100 can comprise a control body 102 and a cartridge 104that can be permanently or detachably aligned in a functioningrelationship. Although a threaded engagement is illustrated in FIG. 1,it is understood that further means of engagement may be employed, suchas a press-fit engagement, interference fit, a magnetic engagement, orthe like.

In specific embodiments, one or both of the control body 102 and thecartridge 104 may be referred to as being disposable or as beingreusable. For example, the control body may have a replaceable batteryor a rechargeable battery and thus may be combined with any type ofrecharging technology, including connection to a typical electricaloutlet, connection to a car charger (i.e., cigarette lighterreceptacle), and connection to a computer, such as through a universalserial bus (USB) cable. For example, an adaptor including a USBconnector at one end and a control body connector at an opposing end isdisclosed in U.S. patent application Ser. No. 13/840,264, filed Mar. 15,2013, which is incorporated herein by reference in its entirety.Further, in some embodiments the cartridge may comprise a single-usecartridge, as disclosed in U.S. patent application Ser. No. 13/603,612,filed Sep. 5, 2012, which is incorporated herein by reference in itsentirety.

In the exemplified embodiment, the control body 102 includes a controlcomponent 106 (e.g., a microcontroller), a flow sensor 108, and abattery 110, which can be variably aligned, and can include a pluralityof indicators 112 at a distal end 114 of an outer body 116. Theindicators 112 can be provided in varying numbers and can take ondifferent shapes and can even be an opening in the body (such as forrelease of sound when such indicators are present). In the exemplifiedembodiment, a haptic feedback component 101 is included with the controlcomponent 106. As such, the haptic feedback component may be integratedwith one or more components of a smoking article for providing vibrationor like tactile indication of use or status to a user. See, for example,the disclosure of U.S. patent application Ser. No. 13/946,309, filedJul. 19, 2013, which is incorporated herein by reference in itsentirety.

An air intake 118 may be positioned in the outer body 116 of the controlbody 102. A coupler 120 also is included at the proximal attachment end122 of the control body 102 and may extend into a control bodyprojection 124 to allow for ease of electrical connection with anatomizer or a component thereof, such as a resistive heating element(described below) when the cartridge 104 is attached to the controlbody. Although the air intake 118 is illustrated as being provided inthe outer body 116, in another embodiment the air intake may be providedin a coupler as described, for example, in U.S. patent application Ser.No. 13/841,233; Filed Mar. 15, 2013.

The cartridge 104 includes an outer body 126 with a mouth opening 128 ata mouthend 130 thereof to allow passage of air and entrained vapor(i.e., the components of the aerosol precursor composition in aninhalable form) from the cartridge to a consumer during draw on theaerosol delivery device 100. The aerosol delivery device 100 may besubstantially rod-like or substantially tubular shaped or substantiallycylindrically shaped in some embodiments. In other embodiments, furthershapes and dimensions are encompassed—e.g., a rectangular or triangularcross-section, or the like.

The cartridge 104 further includes an atomizer 132 comprising aresistive heating element 134 (e.g., a wire coil) configured to produceheat and a liquid transport element 136 (e.g., a wick) configured totransport a liquid. Various embodiments of materials configured toproduce heat when electrical current is applied therethrough may beemployed to form the resistive heating element 134. Example materialsfrom which the wire coil may be formed include Kanthal (FeCrAl),Nichrome, Molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi),Molybdenum disilicide doped with Aluminum (Mo(Si,Al)₂), carbon graphite,and ceramic (e.g., a positive temperature coefficient ceramic). Furtherto the above, representative heating elements and materials for usetherein are described in U.S. Pat. No. 5,060,671 to Counts et al.; U.S.Pat. No. 5,093,894 to Deevi et al.; U.S. Pat. No. 5,224,498 to Deevi etal.; U.S. Pat. No. 5,228,460 to Sprinkel Jr., et al.; U.S. Pat. No.5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S.Pat. No. 5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S.Pat. No. 5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S.Pat. No. 5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol;U.S. Pat. No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 toFleischhauer et al., the disclosures of which are incorporated herein byreference in their entireties.

Electrically conductive heater terminals 138 (e.g., positive andnegative terminals) at the opposing ends of the heating element 134 areconfigured to direct current flow through the heating element andconfigured for attachment to the appropriate wiring or circuit (notillustrated) to form an electrical connection of the heating elementwith the battery 110 when the cartridge 104 is connected to the controlbody 102. Specifically, a plug 140 may be positioned at a distalattachment end 142 of the cartridge 104. When the cartridge 104 isconnected to the control body 102, the plug 140 engages the coupler 120to form an electrical connection such that current controllably flowsfrom the battery 110, through the coupler and plug, and to the heatingelement 134. The outer body 126 of the cartridge 104 can continue acrossthe distal attachment end 142 such that this end of the cartridge issubstantially closed with the plug 140 protruding therefrom.

A reservoir may utilize a liquid transport element to transport anaerosol precursor composition to an aerosolization zone. One suchexample is shown in FIG. 1. As seen therein, the cartridge 104 includesa reservoir layer 144 comprising layers of nonwoven fibers formed intothe shape of a tube encircling the interior of the outer body 126 of thecartridge, in this embodiment. An aerosol precursor composition isretained in the reservoir layer 144. Liquid components, for example, canbe sorptively retained by the reservoir layer 144. The reservoir layer144 is in fluid connection with a liquid transport element 136. Theliquid transport element 136 transports the aerosol precursorcomposition stored in the reservoir layer 144 via capillary action to anaerosolization zone 146 of the cartridge 104. As illustrated, the liquidtransport element 136 is in direct contact with the heating element 134that is in the form of a metal wire coil in this embodiment.

It is understood that an aerosol delivery device that can bemanufactured according to the present disclosure can encompass a varietyof combinations of components useful in forming an electronic aerosoldelivery device. Reference is made for example to the reservoir andheater system for controllable delivery of multiple aerosolizablematerials in an electronic smoking article disclosed in U.S. patentapplication Ser. No. 13/536,438, filed Jun. 28, 2012, which isincorporated herein by reference in its entirety. Further, U.S. patentapplication Ser. No. 13/602,871, filed Sep. 4, 2012, discloses anelectronic smoking article including a microheater, and which isincorporated herein by reference in its entirety.

Reference also is made to U.S. Pat. Pub. No. 2013/0213419, whichdiscloses a ribbon of electrically resistive mesh material that may bewound around a wick, and to U.S. Pat. Pub. No. 2013/0192619, whichdiscloses a heater coil about a wick wherein the coil windings havesubstantially uniform spacing between each winding. In certainembodiments according to the present disclosure, a heater may comprise ametal wire, which may be wound with a varying pitch around a liquidtransport element, such as a wick. An exemplary variable pitch heaterthat may be used according to the present disclosure is described inU.S. patent application Ser. No. 13/827,994, filed Mar. 14, 2013, thedisclosure of which is incorporated herein by reference in its entirety.

Reference also is made to a liquid supply reservoir formed of anelastomeric material and adapted to be manually compressed so as to pumpliquid material therefrom, as disclosed in U.S. Pat. Pub. No.2013/0213418. In certain embodiments according to the presentdisclosure, a reservoir may particularly be formed of a fibrousmaterial, such as a fibrous mat or tube that may absorb or adsorb aliquid material.

In another embodiment substantially the entirety of the cartridge may beformed from one or more carbon materials, which may provide advantagesin terms of biodegradability and absence of wires. In this regard, theheating element may comprise a carbon foam, the reservoir may comprisecarbonized fabric, and graphite may be employed to form an electricalconnection with the battery and controller. Such carbon cartridge may becombined with one or more elements as described herein for providingillumination of the cartridge in some embodiments. An example embodimentof a carbon-based cartridge is provided in U.S. patent application Ser.No. 13/432,406; filed Mar. 28, 2012, which is incorporated herein byreference in its entirety.

In use, when a user draws on the article 100, the heating element 134 isactivated (e.g., such as via a flow sensor), and the components for theaerosol precursor composition are vaporized in the aerosolization zone146. Drawing upon the mouthend 130 of the article 100 causes ambient airto enter the air intake 118 and pass through the central opening in thecoupler 120 and the central opening in the plug 140. In the cartridge104, the drawn air passes through an air passage 148 in an air passagetube 150 and combines with the formed vapor in the aerosolization zone146 to form an aerosol. The aerosol is whisked away from theaerosolization zone 146, passes through an air passage 152 in an airpassage tube 154, and out the mouth opening 128 in the mouthend 130 ofthe article 100.

The various components of an aerosol delivery device according to thepresent disclosure can be chosen from components described in the artand commercially available. Examples of batteries that can be usedaccording to the disclosure are described in U.S. Pat. App. Pub. No.2010/0028766, the disclosure of which is incorporated herein byreference in its entirety.

An exemplary mechanism that can provide puff-actuation capabilityincludes a Model 163PC01D36 silicon sensor, manufactured by theMicroSwitch division of Honeywell, Inc., Freeport, Ill. Further examplesof demand-operated electrical switches that may be employed in a heatingcircuit according to the present disclosure are described in U.S. Pat.No. 4,735,217 to Gerth et al., which is incorporated herein by referencein its entirety. Further description of current regulating circuits andother control components, including microcontrollers that can be usefulin the present aerosol delivery device, are provided in U.S. Pat. Nos.4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No.5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhaueret al., and U.S. Pat. No. 7,040,314 to Nguyen et al., all of which areincorporated herein by reference in their entireties.

Reference also is made to International Publications WO 2013/098396, WO2013/098397, and WO 2013/098398, which describe controllers configuredto control power supplied to a heater element from a power source as ameans to monitor a status of the device, such as heater temperature, airflow past a heater, and presence of an aerosol forming material near aheater. In particular embodiments, the present disclosure provides avariety of control systems adapted to monitor status indicators, such asthrough communication of a microcontroller in a control body and amicrocontroller or other electronic component in a cartridge component.

The aerosol precursor, which may also be referred to as an aerosolprecursor composition or a vapor precursor composition, can comprise oneor more different components. For example, the aerosol precursor caninclude a polyhydric alcohol (e.g., glycerin, propylene glycol, or amixture thereof). Representative types of further aerosol precursorcompositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr.et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 toBiggs et al.; and Chemical and Biological Studies on New CigarettePrototypes that Heat Instead of Burn Tobacco, R. J. Reynolds TobaccoCompany Monograph (1988); the disclosures of which are incorporatedherein by reference. In some embodiments, the aerosol precursor fluidcan include water in an amount that is greater than about 0.1% and lessthan about 15% by weight. For example, water can be present in an amountof about 1% by weight to about 15% by weight, about 2% by weight toabout 14% by weight, or about 5% by weight to about 13% by weight.

Still further components can be utilized in the aerosol delivery deviceof the present disclosure. For example, U.S. Pat. No. 5,154,192 toSprinkel et al. discloses indicators that may be used with smokingarticles; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. disclosespiezoelectric sensors that can be associated with the mouth-end of adevice to detect user lip activity associated with taking a draw andthen trigger heating; U.S. Pat. No. 5,372,148 to McCafferty et al.discloses a puff sensor for controlling energy flow into a heating loadarray in response to pressure drop through a mouthpiece; U.S. Pat. No.5,967,148 to Harris et al. discloses receptacles in a smoking devicethat include an identifier that detects a non-uniformity in infraredtransmissivity of an inserted component and a controller that executes adetection routine as the component is inserted into the receptacle; U.S.Pat. No. 6,040,560 to Fleischhauer et al. describes a defined executablepower cycle with multiple differential phases; U.S. Pat. No. 5,934,289to Watkins et al. discloses photonic-optronic components; U.S. Pat. No.5,954,979 to Counts et al. discloses means for altering draw resistancethrough a smoking device; U.S. Pat. No. 6,803,545 to Blake et al.discloses specific battery configurations for use in smoking devices;U.S. Pat. No. 7,293,565 to Griffen et al. discloses various chargingsystems for use with smoking devices; U.S. Pat. No. 8,402,976 toFernando et al. discloses computer interfacing means for smoking devicesto facilitate charging and allow computer control of the device; U.S.Pat. App. Pub. No. 2010/0163063 by Fernando et al. disclosesidentification systems for smoking devices; U.S. Pat. App. Pub. No.2013/0213418 to Tucker et al. discloses means for aerosol productionthrough heating of a capillary tube; WO 2010/003480 to Flick discloses afluid flow sensing system indicative of a puff in an aerosol generatingsystem; and WO 2013/102612 to Greim et al. discloses a charging devicefor an electronic smoking article, all of the foregoing disclosuresbeing incorporated herein by reference in their entireties. Furtherexamples of components related to electronic aerosol delivery articlesand disclosing materials or components that may be used in the presentarticle include U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No.5,249,586 to Morgan et al.; U.S. Pat. No. 5,388,574 to Ingebrethsen;U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 toAdams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat No. 6,196,218to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No.6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No.7,513,253 to Kobayashi; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No.6,772,756 to Shayan; U.S. Pat. No. 8,156,944 to Hon; U.S. Pat. No.8,365,742 to Hon; U.S. Pat. No. 8,375,957 to Hon; U.S. Pat. No.8,393,331 to Hon; U.S. Pat. App. Pub. Nos. 2006/0196518 and 2009/0188490to Hon; U.S. Pat. App. Pub. No. 2009/0272379 to Thorens et al.; U.S.Pat. App. Pub. Nos. 2009/0260641 and 2009/0260642 to Monsees et al.;U.S. Pat. App. Pub. Nos. 2008/0149118 and 2010/0024834 to Oglesby etal.; U.S. Pat. App. Pub. No. 2010/0307518 to Wang; WO 2010/091593 toHon; WO 2013/089551 to Foo; WO 2013/083631 and WO 2013/083634 to Dubiefet al.; WO 2013/098396 to Talon et al.; WO 2013/102611 to Greim et al.;U.S. Pat. App. Pub. No. 2013/0192615 to Tucker et al.; U.S. Pat. App.Pub. No. 2013/0192621 to Li et al.; and U.S. patent application Ser. No.13/841,233, filed Mar. 15, 2013, each of which is incorporated herein byreference in its entirety. A variety of the materials disclosed by theforegoing documents may be incorporated into the present devices invarious embodiments, and all of the foregoing disclosures areincorporated herein by reference in their entireties.

The foregoing description of use of the article can be applied to thevarious embodiments described herein through minor modifications, whichcan be apparent to the person of skill in the art in light of thefurther disclosure provided herein. The above description of use,however, is not intended to limit the use of the article but is providedto comply with all necessary requirements of disclosure of the presentdisclosure.

A further exemplary embodiment of a smoking article 200 according to thepresent disclosure is shown in FIG. 2. As illustrated therein, a controlbody 202 can be formed of a housing 201 that can include a controlcomponent 206, a flow sensor 208, a battery 210, and an LED 212. Acartridge 204 can be formed of a housing 203 enclosing a reservoir 244that is in fluid communication with a transport element 236 adapted towick or otherwise transport an aerosol precursor composition stored inthe reservoir to a heater 234. An opening 228 may be present in thecartridge housing 203 to allow for egress of formed aerosol from thecartridge 204. Such components are representative of the components thatmay be present in a cartridge and are not intended to limit the scope ofcartridge components that are encompassed by the present disclosure. Thecartridge 204 may be adapted to engage the control body 202 through apress-fit engagement between the control body projection 224 and thecartridge receptacle 240. Such engagement can facilitate a stableconnection between the control body 202 and the cartridge 204 as well asestablish an electrical connection between the battery 210 and controlcomponent 206 in the control body and the heater 234 in the cartridge.The cartridge 204 also may include one or more electronic components250, which may include an IC, a memory component, a sensor, or the like.The electronic component 250 may be adapted to communicate with thecontrol component 206.

In various embodiments, the present disclosure particularly can providefor improved control of fluid passage (particularly water, includingwater vapor) into and/or out of a housing in which a reservoir iscontained such as, for example, a smoking article (and particularly acartridge thereof). For example, in some embodiments, the presentdisclosure can provide for improving retention of an aerosol precursorcomposition in a housing, particularly within its reservoir, and thusprevent or reduce leaking of the liquid out of the housing. In someembodiments, the present disclosure can provide for preventing orreducing ingress of moisture (e.g., water vapor) into a housing. In someembodiments, the present disclosure can provide for preventing orreducing dilution of an aerosol precursor composition in a reservoirsuch as may occur through absorption of water vapor from air. Suchmoisture control can relate to the nature of the smoking article itself,methods of manufacturing of the smoking article, methods of packaging ofthe smoking article, and combinations thereof.

Returning to FIG. 2, the cartridge 204 can be substantially tubular inshape. As such, the reservoir 244 likewise can be substantially tubularin shape (see FIG. 3) and can be formed of a reservoir wall 245. Thereservoir 244 can be substantially rod-like or substantially tubularshaped or substantially cylindrically shaped. Thus, the reservoir 244can have a diameter such that the reservoir can be adapted to fit withinthe housing forming cartridge 204. The reservoir 244 can be formed froma plurality of combined layers that can be concentric or overlapping.For example, the reservoir 244 can be a continuous sheet of materialthat is rolled to form the hollow tube. The reservoir 244 can be a wovenor non-woven material. For example, the reservoir 244 may be a mat ofnonwoven material. In other embodiments, the reservoir 244 can besubstantially a unitary component. For example, the reservoir 244 can beshaped or molded so as to be a singular element in the form of asubstantially hollow tube that is substantially continuous incomposition across the length and thickness thereof. The reservoir 244can be rigid or semi-rigid. If desired, one or more additionalcomponents of a smoking article according to the present disclosure canbe accommodated within or around the reservoir 244. While the reservoir244 is shown in the cartridge 204 portion of a smoking article in FIG.2, one skilled in the art will appreciate that the reservoir can bepositioned within any portion of a smoking article so as not to impedethe storage and delivery of an aerosol precursor composition storedtherein.

In certain embodiments, a reservoir according to the present disclosurecan be provided in a form such that at least part of the hollow interiorthereof is shaped and dimensioned to accommodate one or more furthercomponents of the smoking article. In some embodiments, the term “shapedand dimensioned” can indicate that a wall of the hollow interiorincludes one or more indentations or protrusions that cause the interiorto have a shape that is other than substantially smooth and continuous.In other embodiments, the hollow nature of the reservoir can besufficient to allow for accommodation of further components of thesmoking article without the need for formation of cavities orprotrusions. This particularly can facilitate ease of assembly of thesmoking article and can maximize the reservoir volume while alsoproviding sufficient space for aerosol formation. As seen in FIG. 3, theexterior surface of the reservoir 244 can be adapted to conform to theinterior surface of the housing forming the cartridge 204. The reservoir244 can have an inner surface that defines a central cavity 246 of thereservoir. In some embodiments, the inner surface of the reservoir maybe characterized as being shaped and dimensioned to accommodate anatomizer 300 in that the atomizer can be positioned with the centralcavity 246 such that a portion of the atomizer is in fluid connectionwith the reservoir.

The atomizer 300 can comprise a heater, a liquid transport element, andelectrically conducting terminals (which may be optional). In theillustrated embodiments, the liquid transport element is a continuous,elongated wick 309, and the heater is a resistive heating coil 310 thatis in connection with the wick and is positioned at about a midpoint ofthe wick. The portions of the wick 309 extending beyond the resistiveheating coil 310 can be referred to as distal arms of the wick. Theelectrically conducting terminals 311 of the atomizer 300 are positionedin contact with the wick 309 distal to the resistive heating coil 310.The electrically conducting terminals 311 particularly can becharacterized as being in contact with the wick 309 at one or moreportions of the wick distal to the resistive heating coil 310. Asillustrated, the electrically conducting terminals 311 extend beyond theends of the wick 309. Such extension is not necessarily required. Inlight of the nature of the reservoir 244 with its hollow interiorportion, an atomizer can be easily positioned interior to the reservoirduring assembly of the smoking article. Likewise, as the hollow interiorcan be shaped and dimensioned to mate with the atomizer, the combinationcan be easily assembled, and the atomizer can snugly mate with thereservoir while simultaneously placing the wick in fluid connection withthe reservoir.

The reservoir can be manufactured from any material capable of beingshaped into a rigid or semi-rigid hollow tube while retaining theability to store a liquid product such as, for example, an aerosolprecursor composition, particularly an aerosol precursor fluid. Incertain embodiments, the reservoir material can be absorbent, adsorbent,or otherwise porous so as to provide the ability to retain the aerosolprecursor composition. As such, the aerosol precursor composition can becharacterized as being coated on, adsorbed by, or absorbed in thereservoir material. The reservoir can be positioned within the smokingarticle to be in substantial contact with one or more transport elements(e.g., wicks). More particularly, a reservoir can be manufactured fromany material suitable for retaining the aerosol precursor composition(e.g., through absorption, adsorption, or the like) and allowing wickingaway of the precursor composition for transport to the resistive heatingelement.

The reservoir material is suitable for forming and maintaining anappropriate conformation, such as a substantially tubular shape, and foraccommodating therein the suitable components of the smoking article.The reservoir material can be heat resistant so as to retain itsstructural integrity—e.g., does not degrade—at least at a temperaturethat is received in a position proximal to the heating temperatureprovided by the resistive heating element. The size and strength of thereservoir may vary according to the features and requirements of thecorresponding electronic smoking article. In particular embodiments, thereservoir can be manufactured from a material suitable for a high-speed,automated manufacturing process. In certain embodiments, the reservoircan comprise a woven or non-woven fibrous mat, which may be rolled orotherwise formed into a tube or hollow cylinder shape. In otherembodiments, the reservoir can be a molded tube or hollow cylinder.

According to one embodiment, the reservoir can be manufactured from acellulose acetate tow which can be processed to form a hollow acetatetube. Cellulose acetate tow can be prepared according to variousprocesses known to one skilled in the art. See, for example, theprocesses forth in U.S. Pat. No. 4,439,605 to Yabune, U.S. Pat. No.5,167,764 to Nielsen et al., and U.S. Pat. No. 6,803,458 to Ozaki whichare incorporated herein by reference in their entireties. Typically,cellulose acetate is derived from cellulose by reacting purifiedcellulose from wood pulp with acetic acid and acetic anhydride in thepresence of sulfuric acid. The resulting product is then put through acontrolled, partial hydrolysis to remove the sulfate and a sufficientnumber of acetate groups to produce the required properties for acellulose acetate that is capable of ultimately forming a rigid orsemi-rigid hollow tube. Cellulose acetate can then be extruded, spun,and arranged into a tow. The cellulose acetate fibers can be opened,crimped, or a continuous filament.

In further embodiments, the cellulose acetate can be any acetatematerial of the type that can be employed for providing a tobacco smokefilter for cigarettes. Preferably a traditional cigarette filtermaterial is used, such as cellulose acetate tow or gathered celluloseacetate web. Examples of materials that can be used as an alternative tocellulose acetate include polypropylene tow, gathered paper, strands ofreconstituted tobacco, or the like. One filter material that can providea suitable filter rod and thus a suitable hollow tube reservoir iscellulose acetate tow having 3 denier per filament and 40,000 totaldenier. As another example, cellulose acetate tow having 3 denier perfilament and 35,000 total denier can be used. As another example,cellulose acetate tow having 8 denier per filament and 40,000 totaldenier can be used. For further examples, see the types of filtermaterials set forth in U.S. Pat. No. 3,424,172 to Neurath; U.S. Pat. No.4,811,745 to Cohen et al.; U.S. Pat. No. 4,925,602 to Hill et al.; U.S.Pat. No. 5,225,277 to Takegawa et al. and U.S. Pat. No. 5,271,419 toArzonico et al.; each of which is incorporated herein by reference.

Cellulose acetate fibers can be mixed with other materials, such as,cellulose, viscose, cotton, cellulose acetate-butyrate, cellulosepropionate, polyester—e.g., polyethylene terephthalate (PET), polylacticacid (PLA), activated carbon, glass fibers, metal fibers, wood fibers,and the like. The fibers of a cellulose acetate tow emerging from thespinneret can be bunched together to form a “raw tow” which can becollected into a bale for subsequent processing into a tube as describedherein. Additional examples of fiber materials that can be suitable foruse in a reservoir according to the present disclosure are described inUS Pat Publication No. 2013/0025610 to Sebastian et al., the disclosureof which is incorporated herein by reference.

Cellulose acetate can be processed and formed into a tube usingconventional filter tow processing means. For example, a steam bondingprocess can be used to produce the hollow acetate tubes. Exemplaryprocesses for forming tubes of cellulose acetate can be found US Pat.Publication No. 2012/0255569 to Beard et al. In further embodiments,cellulose acetate can be processed using a conventional filter towprocessing unit. For example, filter tow can be bloomed using bussel jetmethodologies or threaded roll methodologies. An exemplary towprocessing unit has been commercially available as E-60 supplied byArjay Equipment Corp., Winston-Salem, N.C. Other exemplary towprocessing units have been commercially available as AF-2, AF-3 and AF-4from Hauni-Werke Korber & Co. KG, and as Candor-ITM Tow Processor fromInternational Tobacco Machinery. Other types of commercially availabletow processing equipment, as are known to those of ordinary skill in theart, can be employed. Alternative materials for forming the hollow tubereservoir, such as gathered paper, nonwoven polypropylene web, orgathered strands of shredded web, can be provided using the types ofmaterials, equipment and techniques set forth in U.S. Pat. No. 4,807,809to Pryor et al. and U.S. Pat. No. 5,025,814 to Raker. In addition,representative manners and methods for operating a filter materialsupply units and filter-making units are set forth in U.S. Pat. No.4,281,671 to Bynre; U.S. Pat. No. 4,850,301 to Green, Jr. et al.; U.S.Pat. No. 4,862,905 to Green, Jr. et al.; U.S. Pat. No. 5,060,664 toSiems et al.; U.S. Pat. No. 5,387,285 to Rivers and U.S. Pat. No.7,074,170 to Lanier, Jr. et al.

The hollow acetate tubes as described herein can be particularly usefulbecause of a surprisingly efficient liquid storing capacity. Accordingto one embodiment, the cellulose acetate tow can have a linear massdensity of about 0.5 denier per filament (dpf) or greater, about 1 dpfor greater, or about 2 dpf or greater. In other embodiments, thecellulose acetate tow can have a linear mass density of about 0.5 dpf toabout 20 dpf, about 0.75 dpf to about 15 dpf, about 1 dpf to about 10dpf, or about 2 dpf to about 6 dpf. The cellulose acetate used accordingto the present disclosure can comprise staple fibers. The staple fiberscan have an average length of about 0.1 in. to about 6 in., about 0.2in. to about 5 in. or about 0.25 in. to about 3 in.

The reservoir comprising cellulose acetate can be formed of variouscompositions and in various manners. In particular embodiments, thereservoir can comprise cellulose acetate fibers. If desired, thereservoir can comprise a binder. Fillers (e.g., cellulose) and fibersformed of different materials also can be used. The reservoir cancomprise about 70% to about 99% by weight cellulose acetate fibers, andthe weights noted herein are measured on a dry weight basis (i.e.,without any aerosol precursor or other fluid therein). Morespecifically, the reservoir can comprise about 75% to about 98%, about80% to about 97.5%, or about 90% to about 97% by weight celluloseacetate fibers. The reservoir can comprise about 1% to about 30% byweight of the binder. More specifically, the reservoir can compriseabout 2% to about 25%, about 2.5% to about 20%, or about 3% to about 10%by weight of the binder. In specific embodiments, a reservoir accordingto the disclosure can comprise about 95% to about 97% by weightcellulose acetate fiber and about 3% to about 5% by weight binder. Inother specific embodiments, a reservoir according to the disclosure cancomprise about 80% to about 85% by weight cellulose acetate fiber andabout 15% to about 20% by weight binder. A binder is understood to be amaterial that imparts a cohesive effect to the fibers used in formingthe disclosed reservoirs. For example, the binder can be a material thatpartially solubilizes the cellulose acetate fibers such that the fibersbind to each other or to further fibrous materials included in the wovenor non- woven reservoir. Exemplary binders that can be used includepolyvinyl acetate (PVA) binders, starch, and triacetin. One of skill inthe art of cigarette filter manufacture may recognize triacetin as beinga plasticizer for such filters. As such, it is understood that there maybe overlap between the group of binders useful according to the presentdisclosure and materials that may be recognized in further arts asplasticizers. Accordingly, the cohesion agent used and described hereinas a binder may encompass materials that may be recognized in otherfields as being plasticizers. Moreover, materials recognized in thefield of cigarette filters as plasticizers for cellulose acetate may beencompassed by the use of the term binders herein.

The cellulose acetate fibers can have various cross-sectionalshapes—e.g., round, elongated, or multi-lobal. In specific embodiments,cellulose acetate having a tri-lobal or Y-shaped cross-sectional shapecan be used.

In some embodiments, a non-woven fibrous mat reservoir according to thepresent disclosure can be formed by a wet-laid process or by a dry-laidprocess. When using a wet-laid process, it can be beneficial to usecellulose acetate fibers having shorter lengths—e.g., in the range ofabout 0.25 in. to about 2 in. When using a dry-laid process, it can bebeneficial to use cellulose acetate fibers having longer lengths—e.g.,in the range of about 2.5 in. to about 3 in. In each case, a resultingmat comprising the cellulose acetate fibers can be at a thickness ofabout 1 mm to about 4 mm, about 1.25 mm to about 3.5 mm, or about 1.5 mmto about 3 mm. The cellulose acetate mat can be sized to a desiredwidth. In various embodiments, the width can be about 10 mm to about 25mm, about 15 mm to about 24 mm, or about 20 mm to about 23 mm. Thecellulose acetate mats can be cut to lengths suitable to be rolled intoa tube having an outer diameter suitable for insertion into a smokingarticle as described herein and having an inner diameter suitable toallow insertion of an atomizer therein according to the presentdisclosure. The ends of the rolled mats can form a butt joint or mayoverlap. In further embodiments, the cellulose acetate composition canbe molded into a formed shape that is substantially tubular. The shapedhollow acetate tube can have one or more shapes formed into the innerwall thereof, such as the diametrically opposed grooves discussed above.

In some embodiments, the fibers of the formed mats can be entangled. Forexample, hydroentangling and needle punching each can be used separatelyor in combination. In specific embodiments, needle punching can be usedwith at least 250, at least 500, at least 1,000, or at least 1,500needle punches per square inch (NPPSI). In particular, about 250 toabout 2,500, about 500 to about 2,000, or about 750 to about 1,500 NPPSIcan be used.

According to one embodiment, the reservoir can comprise a mixture ofdifferent types of fibers. Suitable fibers for forming such mixtureinclude, but are not limited to, fibers formed from cellulose acetate,wood pulp, wool, silk, polyesters (e.g., polyethylene terephthalate)polyamides (e.g., nylons), polyolefins, polyvinyl alcohol, and the like.

It has been found according to the present disclosure that hydrophilicfibers, particularly cellulose acetate, can be particularly useful informing a reservoir for an aerosol precursor composition, particularly acomposition formed predominately with a polyhydric alcohol, such asglycerin. Such reservoirs can provide improved storage and release ofthe aerosol precursor composition. For example, such reservoirs canprovide for faster loading of the aerosol precursor composition, formore consistent release of the aerosol precursor composition when drawnaway, such as by a wick, during use of the smoking article, and areduction in the total volume of aerosol precursor composition that mustbe loaded in the reservoir.

In various embodiments, the improved moisture control afforded byelectronic smoking articles according to the present disclosure canarise from the nature of the device and its construction, materials usedin the construction, and methods of constructing the device. Forexample, it has been found that a reservoir comprising a woven ornonwoven fabric can provide improved retention of fluid absorbed thereinor adsorbed thereon when the fabric is provided in a defined weightbases. In non-limiting embodiments, a woven or nonwoven fabric useful ina reservoir according to the present disclosure can have a basis weightof about 120 grams per square meter (gsm) or greater, about 125 gsm orgreater, or about 130 gsm or greater. In further embodiments, the wovenor nonwoven fabric can have a basis weight of about 120 gsm to about 220gsm, about 125 gsm to about 200 gsm, or about 130 gsm to about 180 gsm.

It has been found that a reservoir for use in an electronic smokingarticle can suffer from its inherent absorptive or adsorptive propertiesin that water vapor may be taken up from surrounding air, particularlyduring storage, and thus dilute the aerosol precursor compositionalready provided therein. In some instances, the amount of water vaporcaptured by the reservoir can exceed its holding capacity, and“sweating” can occur wherein liquid releases from the reservoir into theinterior of the housing forming the smoking article. This movement ofliquid through the device can have deleterious effects in relation tocorrosion and possible interference or other interaction with electricalcomponents of the device. Moreover, depending upon the nature of thehousing, liquid released by the reservoir may move out of the housing,which may be unfavorable to a consumer.

A common consideration for a reservoir in an electronic smoking articleis the ability of the reservoir to hold a sufficient volume of aerosolprecursor composition to form the desired amount of aerosol. In light ofthe relatively small size of many electronic smoking articles, it istypically desirable to limit the size of components, including thereservoir, to only the absolutely necessary maximum dimensions (e.g.,length and diameter). It has been recognized according to the presentdisclosure, however, that utilization of a high basis weight woven ornonwoven fabric in the reservoir of an electronic smoking article can beeffective to prevent or reduce loss of aerosol precursor liquid from thereservoir into the open housing of the device. The increased basisweight can provide a greater holding capacity without the need tosignificantly increase the absolute dimensions (e.g., the length anddiameter) of the reservoir.

In addition or in the alternate to increased basis weight, the abilityof the reservoir to retain the aerosol precursor composition in liquidform can be improved through surface treatment of the reservoir. Forexample, one or more surfaces of the reservoir can be treated to reduceor prevent passage of liquid therethrough. For example, a hydrophobicmaterial can be used. The liquid transport element can thus provide theonly or main conduit for passage of any liquid out of the reservoir.

In other embodiments, sweating of a reservoir may be reduced oreliminated by limiting the total amount of aerosol precursor compositionthat is applied to the woven or nonwoven fabric. In particular, thearticle may be limited such that the weight of aerosol precursor fluidthat is stored in the reservoir does not exceed a defined weightrelative to the saturation capacity of the reservoir. An absorptive oradsorptive reservoir can exhibit a saturation capacity, which can bedefined as the mass of a liquid that may be retained by a reservoir of adefined composition and mass above which the reservoir can no longerabsorb or adsorb any further amount of the liquid.

A material useful as a reservoir according to the present disclosure canhave a saturation capacity of up to about 2,000%, up to about 1,900%, orup to about 1,800% by weight relative to an aerosol precursorcomposition useful according to the present disclosure. In furtherembodiments, a reservoir can have a saturation capacity of about 800% toabout 2,000%, about 900% to about 1,800%, about 1,000% to about 1,700%,or about 1,200% to about 1,600% by weight.

In some embodiments, the weight of aerosol precursor fluid in thereservoir relative to the saturation capacity of the reservoir is nogreater than about 80%. For example, a fabric reservoir having a weightof 5 g and a saturation capacity of about 1,500% by weight relative toan aerosol precursor composition can hold a maximum of about 75 g of theaerosol precursor composition. Such reservoir loaded with no greaterthan about 80% of the saturation capacity would be loaded with nogreater than about 48 g of the aerosol precursor composition. In furtherembodiments, the weight of aerosol precursor fluid in the reservoirrelative to the saturation capacity of the reservoir is no greater thanabout 60%. By thus limiting the weight of aerosol precursor fluidoriginally loaded into the reservoir, the amount of water vapor that maybe taken up during storage may be insufficient to load the reservoirsufficiently near or beyond its saturation capacity and cause sweatingor similar release of fluid from the reservoir.

The filaments used in a wick according to the present disclosure can beformed of any material that provides sufficient wicking action totransport one or more components of the aerosol precursor compositionalong the length of the filament. Non-limiting examples include naturaland synthetic fibers, such as cotton, cellulose, polyesters, polyamides,polylactic acids, glass fibers, combinations thereof, and the like.Other exemplary materials that can be used in wicks include metals,ceramics, and carbonized filaments (e.g., a material formed of acarbonaceous material that has undergone calcining to drive offnon-carbon components of the material). Exemplary materials that may beused as a wick according to the present disclosure are described in U.S.patent application Ser. No. 13/802,950, filed Mar. 13, 2013, thedisclosure of which is incorporated herein by reference in its entirety.

In particular embodiments, a wick useful as the liquid transportcomponent is a braided wick. The braided wick can be formed from atleast 3 separate fibers or yarns. Further, the braided wick can beformed from at least 4, at least 6, at least 8, at least 10, at least12, at least 14, or at least 16 separate fibers or yarns. Each of theseparate fibers or yarns may be identical in composition. Alternatively,the separate fibers or yarns may comprise fibers or yarns formed of twoor more different compositions (e.g., a fiberglass yarn braided with acotton yarn). Thus, the braided wick can be formed of a plurality ofsynthetic fibers or yarns, a plurality of natural fibers or yarns, of acombination of at least one synthetic fiber or yarn and at least onenatural fiber or yarn. In certain embodiments, E-glass can be used. Insome embodiments, C-glass can be used.

A braided wick in particular may be provided as a component of asheath/core yarn. In particular, a first wick material can form a yarncore, and a second wick material can surround the core to form a yarnsheath. The sheath and core can differ in at least one of physicalstructure and the material from which the yarn is formed. In a preferredexample, a twisted yarn can comprise the core, and braided yarn can formthe sheath.

Devices according to the present disclosure can include even furtherelements useful in controlling moisture. In some embodiments, one ormore mechanical elements can be included in an electronic smokingarticle, such as a cartridge thereof, and can be adapted to preventfluid passage across a barrier. For example, in some embodiments, anelectronic smoking article according to the present disclosure cancomprise a housing having an air inlet adapted for entry of air into thehousing and an air outlet adapted for exit of a formed aerosol, theinlet and the outlet having an air passage therebetween. The smokingarticle further can comprise a reservoir within the housing that isconfigured to hold an aerosol precursor fluid and a heater in fluidcommunication with the reservoir. Still further, the smoking article caninclude one or more valves adapted to prevent fluid passage across abarrier. For example, a first check valve can be positioned at the airinlet and a second check valve can be positioned at the air outlet.

One embodiment of a cartridge 404 according to the present disclosure isshown in FIG. 4. As seen therein, the cartridge 404 comprises a housing403 with a housing receptacle 440 at a first end thereof that is adaptedto interconnect with a control body projection (see element 224 in FIG.2, for example). One or more cut-outs may be formed in the housing 403at the first end thereof to form an air inlet 418. A plurality of airinlets 418 (one to five, for example) may be included. At least one airoutlet 428 can be provided at a second, opposing end of the housing 403.As illustrated, the housing 403 further includes a reservoir 444, whichmay have a construction as otherwise disclosed herein. The reservoir insome embodiments can be substantially cylindrical. As seen in FIG. 4, anair passage 480 interconnects the air inlet 418 and the air outlet 428and passes through the interior opening of the cylindrical reservoir444. The cartridge 404 also can include a first end wall 460 formedadjacent the housing receptacle 440 and forming a terminal base thereof.Formed in the first end wall 460 is a first check valve 465. A secondend wall 470 is included near the second end of the housing 403. Formedin the second end wall 470 is a second check valve 475. In the firstcheck valve 465 and second check valve 475 as illustrated, a simple flapvalve is shown in an open position indicating air flow passing throughthe device. A variety of valves, however, may be utilized, such as ballvalves and heart valves.

The first end wall 460 and second end wall 470 can form a chamber 490that can be adapted to retain all liquids (e.g., aerosol precursorcomposition or ambient water vapor entrained during manufacturing)therein. The first check valve 465 and second check valve 475 inparticular can be adapted to form a seal that is substantially liquidimpermeable (particularly water and vapor) when in the closed position.As such, any sweating or other loss of liquid from the reservoir 444 maybe retained completely within the chamber 490 so as to disallow anyleakage through the first end (e.g., the housing receptacle 440) orsecond end (e.g., the mouth end 430) of the housing 403.

The first check valve and the second check valve may be adapted to openonly in the direction of air flow from the air inlet to the air outlet(the air flow being illustrated by the dashed arrows in FIG. 4). Assuch, in some embodiments, one or both of the first check valve and thesecond check valve can be one way check valves. In further embodiments,one or both of the first check valve and the second check valve can betwo way check valves, if desired. Any check valve suitably sized forinclusion in a device as described herein may be used.

As illustrated in FIG. 4, a cartridge 404 also may include an atomizerformed of a transport element 436 adapted to wick or otherwise transportan aerosol precursor composition stored in the reservoir 444 to a heater434 that heats and vaporizes the aerosol precursor composition and forman aerosol when mixed with the air flowing through the air passage 480.In some embodiments, the heater can be positioned at least partiallywithin the air passage.

Separately or in combination with the inclusion of check valves asillustrated in FIG. 4, a smoking article according to the presentdisclosure may include an absorptive material. Preferably, theabsorptive material is adapted for absorbing any free liquid within thehousing 403 without substantially withdrawing any of the aerosolprecursor composition from the reservoir 444. The absorptive material,for example, may be a fibrous material formed of natural and/orsynthetic fibers. Porous ceramics and the like also may be used. Inparticular, the absorptive material can be provided as a lining on allor part an interior wall of the housing 403. In some embodiments, asillustrated in FIG. 4, the absorptive material may be located only atone or both of the first end and the second end of the housing 403. InFIG. 4, the absorptive material 495 is located at the respective endsbut interior to the first end wall 460 and the second end wall 470—i.e.,within the chamber 490.

The present disclosure further provides methods of making electronicsmoking articles. In some embodiments, the method can comprise providinga reservoir, which can comprise a woven or nonwoven fabric and which maybe provided in the form of a cylinder having a hollow interior portion.At least part of the hollow interior can be shaped and dimensioned toaccommodate one or more further components of the smoking article. Themethod can further include the step of inserting an atomizer into thehollow interior of the reservoir. The atomizer can comprise a liquidtransport element, a heater, and electrical contacts. The method canfurther include the steps of inserting the cylinder and atomizer into ahollow shell, and connecting the atomizer to a power source. The powersource can be a battery. Portions of the liquid transport element can beattached to or embedded in the reservoir to form a fluid connection thatenables transport of the aerosol precursor composition out of thereservoir. The atomizer can comprise a continuous, elongated wick havingtwo opposing ends. The wick particularly can be a braided wick and/orcan comprise C-glass. The atomizer can further comprise a heater inconnection with the wick and positioned at about a midpoint thereof. Theatomizer also can comprise electrically conducting terminals positionedin physical contact with the wick and in electrical contact with theheater which, in some embodiments, can be a resistive heating element.

The methods of preparing electronic smoking articles according to thepresent disclosure can be adapted to improve moisture control. Inparticular, the methods can be adapted to prevent or reduce theabsorption or adsorption of water vapor (or other vapors) from the airby the reservoir. Such methods can thus ensure that the aerosol formedduring use of the smoking article is substantially identical incomposition to the aerosol precursor composition applied to thereservoir during processing. In particular, it can substantially preventdilution of the formed aerosol with excess water absorbed or adsorbed bythe reservoir during processing, including manufacturing and shipping.

In some embodiments methods according to the present disclosure cancomprise providing a reservoir as described herein. The reservoirspecifically can be configured to hold an aerosol precursor fluid, andthe reservoir can comprise a woven or nonwoven fabric. The methodfurther can comprise inserting the reservoir into a hollow housing, andadding the aerosol precursor fluid to the reservoir. The aerosolprecursor composition can be added to the reservoir one or both ofbefore or after inserting the reservoir into the hollow housing. Thehousing may be a cartridge housing (which may be separate from a controlbody housing). Alternatively, the housing may be a single housing thatencloses both the reservoir and one or both of a power source and acontrol component. Preferably, the assembly steps described herein canbe carried out under an ambient relative humidity that is maintainedbelow a defined percentage. For example, the assembly can be carried outunder an ambient relative humidity of no greater than about 40%, nogreater than about 35%, no greater than about 30%, or no greater thanabout 20%.

In some embodiments, assembly of an electronic smoking article or acomponent thereof (specifically a cartridge component that includes areservoir) can be carried out under conditions adapted to substantiallyprevent absorption or adsorption of any water vapor during assembly.Substantially preventing absorption or adsorption can indicate that thereservoir absorbs or adsorbs less than 1% by weight, preferably lessthan 0.5% by weight, of water from the ambient atmosphere relative tothe dry weight of the reservoir. Conditions adapted to substantiallyprevent absorption or adsorption of any water vapor during assembly caninclude carrying out the assembly under an inert atmosphere. As anon-limiting example, the inert atmosphere can be an argon atmosphere(or similar gas, such as a further noble gas).

In further embodiments, moisture control can be provided in relation tocertain steps of the assembly of the device. For example, in someembodiments, assembly of a device according to the present disclosurecan include engaging an open end of a hollow housing with a cap elementor like end piece. The method particularly can be adapted to providespecific crimping of the housing end to the cap, the crimping beingadapted to form a non-hermetic seal that allows for gas transfer aroundthe seal but that prevents passage of liquid, particularly hydrophilicliquids, around the seal. Such crimping can be particularly useful inpreventing leakage of any free liquid out of a housing of an electronicsmoking article.

In some embodiments, moisture control can be provided in relation topackaging of an electronic smoking article or a component thereof. Suchpackaging methods may relate specifically to any component of anelectronic smoking article comprising a reservoir adapted for storing anaerosol precursor composition. For example, the packaging methods mayparticularly relate to packaging of a cartridge of an electronic smokingarticle—e.g., a housing including a reservoir and being adapted toreleasably engage a control body and/or power source.

In a non-limiting example, a packaging method according to the presentdisclosure can comprise providing a cartridge (or other electronicsmoking article or component thereof) with a reservoir therein. Thereservoir specifically can comprise a woven or nonwoven fabric and canhave an aerosol precursor fluid therein. The method further can comprisepositioning the cartridge within a non-hermetically sealed displaypackage. The display package particularly may be formed of a materialthat is substantially impermeable to water vapor, such as a polymericmaterial (e.g., a thermoplastic material), for example a polycarbonate,a polyester, or the like. The non-hermetically sealed display packagecan be a package that is adapted to store the smoking article in amanner that is visible from outside of the package. The package may benon-hermetically sealed in that the package comprises at least twopieces that releasably engage one another, and the engagement is adaptedto allow limited gas transfer but substantially prevent passage ofliquids (particularly water) therethrough.

The packaging methods further can include additional steps that areadapted to provide for moisture control. For example, in someembodiments, the methods further may comprise covering any opening inthe non-hermetically sealed display package with a water-tight sealingtape. In particular, the water-tight sealing tape can be adapted toprevent transfer of water in a liquid or vapor form. The sealing tapecan be applied, for example over the joint formed by the engagement ofthe two pieces forming the display package. An exemplary display casethat may be utilized in a method as described herein is described inU.S. patent application Ser. No. 29/447,898, filed Mar. 7, 2013, thedisclosure of which is incorporated herein by reference in its entirety.

In a further example, packaging methods may comprise including an insertin the non- hermetically sealed display package. The insert may includea material adapted to control moisture within the package. For example,a desiccant may be included in the insert so as to preferentially absorbwater vapor and substantially prevent absorption or adsorption of watervapor by the reservoir of the electronic smoking article. In anothernon-limiting example the insert may comprise a humidity control devicethat is adapted to maintain a relative humidity within the package thatis within a desired range. Examples of humidity control devices includethose commercially available under the tradenames HUMIDIPAK® or BOVEDA®.In some embodiments, the humidity control device may be adapted tomaintain a relative humidity within the package of about 5% to about50%, about 10% to about 45%, or about 15% to about 40%.

In yet a further example, packaging methods may comprise providing adouble barrier package. Specifically, the electronic smoking article maybe enclosed by a polymeric barrier within the non-hermetically sealeddisplay package. For example, a polymeric barrier, such as avapor-impermeable film, may line the interior of the non-hermeticallysealed display package. Alternatively, the electronic smoking articlemay be wrapped or otherwise sealed within a polymeric bag and placedinside the non-hermetically sealed display package. Still further, theelectronic smoking article may be encased by a blister package andplaced inside the non-hermetically sealed display package. Examples ofblister packs and related packaging may be found in the following: U.S.Pat. No. 3,610,410 to Seeley; U.S. Pat. No. 3,689,458 to Hellstrom; U.S.Pat. No. 3,732,663 to Geldmacher et al.; U.S. Pat. No. 3,792,181 toMahaffy et al.; U.S. Pat. No. 3,812,963 to Zahuranec et al.; U.S. Pat.No. 3,948,394 to Hellstrom; U.S. Pat. No. 3,967,730 to Driscoll et al.;U.S. Pat. No. 4,120,400 to Kotyuk; U.S. Pat. No. 4,169,531 to Wood; U.S.Pat. No. 4,383,607 to Lordahl et al.; U.S. Pat. No. 4,535,890 to Artusi;U.S. Pat. No. 5,009,894 to Hsiao; U.S. Pat. No. 5,033,616 to Wyser; U.S.Pat. No. 5,147,035 to Hartman; U.S. Pat. No. 5,154,293 to Gould; U.S.Pat. No. 5,878,887 to Parker et al.; and U.S. Pat. No. 6,520,329 toFuchs et al., each of which is incorporated herein by reference.

Any of the foregoing embodiments may be combined with other methods andmaterials useful for reducing or preventing undesired liquid passage inan electronic cigarette. For example, U.S. Pat. App. Pub. Nos.2013/0306064 and 2013/0306065 to Thorens et al. disclose a leakagepreventer, and the disclosures of these documents are incorporatedherein by reference in their entireties.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1-24. (canceled)
 25. A method of packaging a cartridge of an electroniccigarette, the method comprising: providing the cartridge with areservoir therein, the reservoir comprising a woven or nonwoven fabricand having an aerosol precursor fluid therein; and positioning thecartridge within a non-hermetically sealed display package formed of amaterial that is substantially impermeable to water vapor; wherein atleast one of the following steps is carried out: covering any opening inthe non-hermetically sealed display package with a water-tight sealingtape; including a desiccant within the non-hermetically sealed displaypackage; including a humidity control device within the non-hermeticallysealed display package, the humidity control device being adapted tomaintain a relative humidity within the package of about 5% to about50%; and enclosing the cartridge with a polymeric barrier within thenon-hermetically sealed display package.
 26. The method of claim 25,wherein the nonwoven fabric comprises cellulose acetate.
 27. The methodof claim 25, wherein the polymeric barrier is lining the interior of thenon-hermetically sealed display package.
 28. The method of claim 25,wherein the polymeric barrier is a blister package encasing thecartridge.